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TODAY, I am gona share the ZVS DRIVER recently I build

These monster Driver can deliver more than 100 Ampere of low voltage DC current and transfer to HIGH VOLTAGE output by using regular TV/MONITOR (TUBE TYPE) flyback

Step 1: Preparation

Fist thing to do is collecting the material and circuits

for the basic ZVS driver scheme you can get it from google or some one else in these forum, its basically a simple circuits with require a few parts

PARTLIST

1. MOSFET (TOSHIBA 2SK4107)

Here I am using the scrap FET that came from my broken MMA Welder machine and it's a TOSHIBA 2SK4107 which based on the data sheet it's able to deliver 60AMP of pulse.

I am using these FET since the IRF250/260 is way to expensive to buy here and I have a lots of JUNK here :)so no point to spend the money if I can get it for FREE

I am using 3 FET'S each Chanel and based on data sheet it can handle 180AMP of Pulse per Chanel (pretty massive for the task)

You may also experiment to used the other type of FET instead.

2. FAST DIODE (RHRP1560)

Also these parts came from junk, I found it in the PSU switching and it's a RHRP1560 which from the data sheet this is a HYPERFAST DIODE rated at 15 A, 400 V - 600 V,

You may also experiment to used the other type of DIODE instead, BUT make sure it's at least a FAST DIODE.

3. RESISTOR (470R / 5W)

I am using 470R rated at 5W since these is also I have on hand (ofcourse came as well from the my junk collection :)

These is also used to limit the Voltage input to the GATE

4. ZENER DIODE (1Watt / 19V)

Here I am using 19V instead of 12V of zener to limit the voltage that came across to the mosfet gate ( I want something HUGE instead :)

5. RESISTOR (10K)

You can use any 10K of the resistor

NEXT Step is Winding the COIL

6. Capacitor

I am using 470n / 400V that also came from PC PSU

You can use more value for better performance, but NOTE never use the electrolyte since it can blown

7. FLYBACK

Using any flyback of the TV / Monitor tube will be fine, Search at google or these site to easy find the HIGH VOLTAGE GROUND COIL pin.

Step 2: WINDING THE COIL

There are 2 coil that must be created, one on the ferit core of the flyback and the other is for the choke.

COIL at FLYBACK

Previously I have done with lots of enamel wire type (size) and what I think better is what I am using now.

Its a enameled wire that came from PC PSU switching transformer, I de assembly them and take the thin one and combine 4 of them and joint become one , the coil is only 4 turn each chanel (so total 8 turn) midle used for the CT (Center Taped)

You can also experiment with LESS or MORE turn to adjust the result.

COIL for CHOKE

Same, These is the same way as winding the coil for flyback, came as well from the enameled PSU Transformer and combine 3 wire in one

Step 3: TESTING

After all parts is soldered in place, examine again and double check all is correct before plug it to the power source

and after all is correct than you are ready to make an arc

Make sure you use the BIG and STRONG cable for the POWER SOURCE, since I have burn out some of my thin wire :(, remember the current flow to these wire is massive, so massive wire is also required.

See the video above to see the MOSTER ARC in action and pump hundrets of voltage.

For my setup,

Before I am using only a transformer that rated at less than 10amp, I got a small arc, and I was thinking of using any other power that able to supply > 100 AMP.

Suddenly my eyes is pointing to the stick welder machine, and after thinking of it for a while I am decide to use it. These is suitable for the setup, since these inverter able to supply unto 160A at 32V DC, Ideal for the Driver.

Make sure you use the THICK wire if you use the bigger current

WARNING ....


NEVER TOUCH ANY WIRE IN THE SECONDARY COIL at the FLYBACK, even it's recently used and UNPLUG from the power source since it's still saving some Voltage residue, SHORT IT TO THE GROUND FIRST FOR THE SAFETY.

YOU ARE DEALING WITH HI VOLTAGE, ONE SMALL MISTAKE CAN BE A FATAL RESULT.

SAFETY, SAFETY, AND SAFETY FIRST

<h3>HI VOLTAGE Cool</h3>
<p>Just doing a full power on the source, I turn the pot in the inverter welder to it's maximum power which is 160Amp and the arc is sooooo huge ... and runing about 25 second the smoke is finally appears :) and it cam from the flyback, What I guess is from the faulty coil, tested every driver parts (FETS, DIODE, etc) all seems normal, than I removed and rewind again with the biger wire and fire again BUT no ARC only a noisy sound, and finally I found that the secondary INSIDE the flyback is burning :( ... tomorrow will be hunting again the flyback :)</p>
Good job man, I wish I could make one of these so easily :)

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